Apparatus, systems, and methods for automated separation of sand from a wellbore slurry

ABSTRACT

Sand separation systems and methods according to which one or more energy sensors are adapted to detect a response to energy imparted to a sand separator of a known type. One or more computers are adapted to communicate with the one or more energy sensors. The one or more computers and/or the one or more energy sensors are pre-tuned. The one or more computers are configured to determine the unknown sand level in the sand separator of the known type based on: the response detected by the one or more energy sensors, and the pre-tuning of the one or more energy sensors and/or the one or more computers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 16/684,967(“the '967 Application”), filed Nov. 15, 2019, the entire disclosure ofwhich is hereby incorporated herein by reference.

The '967 Application claims the benefit of the filing date of, andpriority to, U.S. Application Ser. No. 62/768,418, filed Nov. 16, 2018,the entire disclosure of which is hereby incorporated herein byreference.

The '967 Application also claims the benefit of the filing date of, andpriority to, U.S. Application Ser. No. 62/867,567, filed Jun. 27, 2019,the entire disclosure of which is hereby incorporated herein byreference.

TECHNICAL FIELD

The present disclosure relates generally to sand separators for use inoil and gas operations and, more particularly, to apparatus, systems,and methods for automated separation of sand from a wellbore slurry.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic illustration of a sand separation systemincluding a sand separator, a dump manifold, and a sand pit, accordingto one or more embodiments of the present disclosure.

FIG. 2A is a diagrammatic illustration of an automated choke of the sandseparation system of FIG. 1, according to one or more embodiments of thepresent disclosure.

FIG. 2B is a diagrammatic illustration of the dump manifold of FIG. 1,according to one or more embodiments of the present disclosure.

FIG. 3 is a flow diagram of a method for implementing one or moreembodiments of the present disclosure.

FIG. 4A is a diagrammatic illustration of another sand separation systemincluding a sand separator having a first level of separated sanddisposed therein, energy generators mounted to the sand separator, andenergy sensors to the sand separator, according to one or moreembodiments of the present disclosure.

FIG. 4B is a diagrammatic illustration of the sand separation system ofFIG. 4A in which the sand separator has a second level of separated sanddisposed therein, according to one or more embodiments of the presentdisclosure.

FIG. 4C is a diagrammatic illustration of the sand separation system ofFIG. 4A in which the sand separator has a third level of separated sanddisposed therein, according to one or more embodiments of the presentdisclosure.

FIG. 4D is a diagrammatic illustration of the sand separation system ofFIG. 4A in which the sand separator has a fourth level of separated sanddisposed therein, according to one or more embodiments of the presentdisclosure.

FIG. 5 is a flow diagram of another method for implementing one or moreembodiments of the present disclosure.

FIG. 6A is a diagrammatic illustration of another sand separationsystem, according to an embodiment in which a user manually actuates adump manifold based on an “alarm” signal received from a control unit,according to one or more embodiments of the present disclosure.

FIG. 6B is a diagrammatic illustration of the another sand separationsystem of FIG. 6A, according to another embodiment in which the controlunit actuates the dump manifold based on an input received from theuser, according to one or more embodiments of the present disclosure.

FIG. 6C is a diagrammatic illustration of the another sand separationsystem of FIG. 6A, according to yet another embodiment in which thecontrol unit actuates the dump manifold automatically based ondata/signals received from energy sensors, according to one or moreembodiments of the present disclosure.

FIG. 7 is a flow diagram of yet another method for implementing one ormore embodiments of the present disclosure.

FIG. 8 is a diagrammatic illustration of a computing node forimplementing one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

Referring to FIG. 1, in an embodiment, a sand separation system isschematically illustrated and generally referred to by the referencenumeral 100. The sand separation system 100 is adapted to remove sandfrom a wellbore slurry (e.g., a fracturing (or “frac”) flowback stream,a production stream, or both). The wellbore slurry is adapted to bereceived from a wellbore 105 that traverses one or more subterraneanformations. A wellhead 110 is adapted to receive the wellbore slurryfrom the wellbore 105, as indicated by arrow 115. The wellhead 110serves as the surface termination of the wellbore 105. An automatedchoke 120 is adapted to receive the wellbore slurry from the wellhead110, as indicated by arrow 125, and to adjust the flow of the wellboreslurry exiting the wellhead 110. Turning additionally to FIG. 2A, insome embodiments, the sand separation system 100 includes a pressuresensor 196. Before, during, and/or after the automated choke 120receives the wellbore slurry from the wellhead 110, as indicated by thearrow 125, the pressure sensor 196 is adapted to monitor the pressure ofthe wellbore slurry exiting the wellhead 110. In some embodiments, as inFIGS. 1 and 2A, the sand separation system 100 further includes one ormore computers such as, for example, a control unit 170, is/are adaptedto communicate with the automated choke 120 and to receive data/signalsfrom the pressure sensor 196 or other sensors. For example, one or morecomputers may send control signals to the automated choke 120 and/orreceive choke position data from the automated choke 120. A power source175 provides electrical power to the one or more computers. In someembodiments, the power source 175 is or includes a solar panel, a windturbine, a generator, a power line, or the like. In some embodiments, asin FIG. 1, the one or more computers is/are, include, is/are part of, oris/are further adapted to communicate with a control system (e.g., asupervisory control and data/signals acquisition (SCADA) system, anelectronic drilling recorder (EDR) system, a remote console, or thelike).

The sand separation system 100 includes a sand separator 130, a dumpmanifold 135, and a sand pit 140 (e.g., in the form of, or including, astorage tank), as shown in FIG. 1. The sand separator 130 is adapted toreceive the wellbore slurry from the automated choke 120, as indicatedby arrow 145, which automated choke 120 is consequently adapted toadjust the flow of the wellbore slurry from the wellhead 110 to the sandseparator 130. After receiving the wellbore slurry, the sand separator130 is adapted to separate the wellbore slurry into a fluids stream anda sand stream; the sand stream includes sand, which sand includes sand,other solid materials, or a combination of sand and other solidmaterials. In some embodiments, as in FIG. 1, the sand separation system100 further includes an ultrasonic sensor 146 a, a temperature sensor146 b, and a pressure sensor 146 c. Before, during, and/or after thesand separator 130 separates the wellbore slurry into the fluids streamand the sand stream, the ultrasonic sensor 146 a and the temperaturesensor 146 b are adapted to monitor the amount of sand accumulated inthe sand separator 130, and the pressure sensor 146 c is adapted tomonitor the pressure in the sand separator 130. In some embodiments, asin FIG. 1, the one or more computers (e.g., the control unit 170) is/arefurther adapted to receive data/signals from the ultrasonic sensor 146a, the temperature sensor 146 b, the pressure sensor 146 c, or anycombination thereof. In some embodiments, the ultrasonic sensor 146 ais, includes, or is part of an ultrasonic echo sensor at the sandseparator 130. In some embodiments, the pressure sensor 146 c is orincludes multiple pressure sensors adapted to measure a pressuredifferential across the sand separator 130. In some embodiments, thetemperature sensor 146 b is, includes, or is part of a thermaldispersion switch at the sand separator 130. In some embodiments, thetemperature sensor 146 b is, includes, or is part of a thermal imagingdevice (e.g., a FLIR camera, another infrared camera, or similar opticalsensor). In some embodiments, one or more of the ultrasonic sensor 146a, the temperature sensor 146 b, and the pressure sensor 146 c arelocated internally within the sand separator 130. In some embodiments,in addition to the ultrasonic sensor 146 a, the temperature sensor 146b, and/or the pressure sensor 146 c, another level sensor may be locatedinternally within the sand separator 130.

A pipeline 150 is adapted to receive the fluids stream from the sandseparator 130, as indicated by arrow 155, and to transport the fluidsstream for further processing to other equipment (e.g., a tank battery),another facility (e.g., a customer facility), a sales channel, or anycombination thereof. In some embodiments, as in FIG. 1, the sandseparation system 100 further includes a sand sensor 156 a. Before,during, and/or after the pipeline 150 receives the fluids stream fromthe sand separator 130, as indicated by the arrow 155, the sand sensor156 a is adapted to monitor the amount of sand in the fluids streamexiting the sand separator 130. In some embodiments, as in FIG. 1, theone or more computers (e.g., the control unit 170) is/are furtheradapted to receive data/signals from the sand sensor 156 a. In someembodiments, the sand sensor 156 a is, includes, or is part of a sandprobe erosion detection sensor at the fluid stream outlet of the sandseparator 130. In some embodiments, the sand sensor 156 a may be orinclude an acoustic sensor.

The dump manifold 135 is adapted to receive the sand stream from thesand separator 130, as indicated by arrow 160, and to prevent, allow,and adjust the flow of the sand stream exiting the sand separator 130.In some embodiments, as in FIG. 1, the sand separation system 100further includes a sand sensor 156 b. Before, during, and/or after thedump manifold 135 receives the sand stream from the sand separator 130,as indicated by the arrow 160, the sand sensor 156 b is adapted tomonitor the amount of sand in the sand stream exiting the sand separator130. In some embodiments, as in FIG. 1, the one or more computers (e.g.,the control unit 170) is/are further adapted to receive data/signalsfrom the sand sensor 156 b. In some embodiments, the sand sensor 156 bis, includes, or is part of a sand probe erosion detection sensor at thefluid stream outlet of the sand separator 130. In some embodiments, thesand sensor 156 b may be or include an acoustic sensor.

Turning additionally to FIG. 2B, in some embodiments, the sandseparation system 100 further includes pressure sensors 176 a and 176 b.Before, during, and/or after the dump manifold 135 receives the sandstream from the sand separator 130, as indicated by the arrow 160, thepressure sensor 176 a is adapted to monitor the pressure of the sandstream entering the dump manifold 135. Similarly, before, during, and/orafter the sand pit 140 receives the sand stream from the dump manifold135, as indicated by the arrow 165, the pressure sensor 176 b is adaptedto monitor the pressure of the sand stream exiting the dump manifold135. In some embodiments, as in FIG. 2B, the one or more computers(e.g., the control unit 170) is/are further adapted to receivedata/signals from the pressure sensor 176 a, the pressure sensor 176 b,or both.

As shown in FIG. 2B, in an embodiment, the dump manifold 135 includes anautomated choke 180 and automated valves 185 a-b. The automated choke180 is adapted to receive the sand stream from the sand separator 130.The automated valves 185 a-b are adapted to receive the sand stream fromthe automated choke 180. As a result, the automated choke 180 and theautomated valves 185 a-b, in combination, define a first flow pathbetween the sand separator 130 and the sand pit 140. The automatedvalves 185 a-b are adapted to allow or prevent flow of the sand streamexiting the sand separator 130 via the first flow path. Thus, when theautomated valves 185 a-b are closed, flow of the sand stream exiting thesand separator 130 via the first flow path is prevented, or at leastreduced. In contrast, when the automated valves 185 a-b are open, flowof the sand stream exiting the sand separator 130 via the first flowpath is allowed and the automated choke 180 is adapted to adjust theflow of the sand stream from the sand separator 130 to the sand pit 140via the first flow path. In some embodiments, as in FIG. 2B, the one ormore computers (e.g., the control unit 170) is/are further adapted tocommunicate with the automated choke 180, the automated valves 185 a-b,or any combination thereof. For example, the one or more computers maysend control signals to the automated choke 180 and/or receive chokeposition data from the automated choke 180. For another example, the oneor more computers may send control signals to the automated valves 185a-b and/or receive valve position data from the automated valves 185a-b.

In some embodiments, the automated choke 180 is a pneumatic choke suchas, for example, a 2-inch pneumatic choke. However, the automated choke180 may be smaller or larger than 2-inches. In some embodiments, one orboth of the automated valves 185 a-b are gate valves such as, forexample, 2-inch pneumatic gate valves. In other embodiments, one or moreof the automated choke 180 and the automated valves 185 a-b may insteadbe hydraulically or electrically actuable. In some embodiments, theautomated choke 180 and the automated valves 185 a-b are rated for10,000 psi (i.e., each has a 10k rating). However, the automated choke180 and the automated valves 185 a-b may be rated for higher or lowerthan 10,000 psi. Although FIG. 2B illustrates one arrangement of theautomated choke 180 and the automated valves 185 a-b defining the firstflow path, the automated choke 180 and the automated valves 185 a-b mayinstead be rearranged to define the first flow path in any order withoutdeparting from the scope of the present disclosure.

In some embodiments, as in FIG. 2B, the dump manifold 135 furtherincludes a manual choke 190 and manual valves 195 a-b. The manual valves195 a-b are adapted to receive the sand stream from the sand separator130. The manual choke 190 is adapted to receive the sand stream from themanual valves 195 a-b. As a result, the manual choke 190 and the manualvalves 195 a-b, in combination, define a second flow path between thesand separator 130 and the sand pit 140. The manual valves 195 a-b areadapted to allow or prevent flow of the sand stream exiting the sandseparator 130 via the second flow path. Thus, when the manual valves 195a-b are closed, flow of the sand stream exiting the sand separator 130via the second flow path is prevented, or at least reduced. In contrast,when the manual valves 195 a-b are open, flow of the sand stream exitingthe sand separator 130 via the second flow path is allowed and themanual choke 190 is adapted to adjust the flow of the sand stream fromthe sand separator 130 to the sand pit 140 via the second flow path.

In some embodiments, the manual choke 190 is a 2-inch manual choke.However, the manual choke 190 may be smaller or larger than 2-inches. Insome embodiments, one or both of the manual valves 195 a-b are plugvalves such as, for example, 2-inch plug valves. Although FIG. 2Billustrates one arrangement of the manual choke 190 and the manualvalves 195 a-b defining the second flow path, the manual choke 190 andthe manual valves 195 a-b may instead be rearranged to define the secondflow path in any order without departing from the scope of the presentdisclosure. In some embodiments, the manual choke 190 and the manualvalves 195 a-b provide additional capacity for dumping of the sandaccumulated in the sand separator 130 into the sand pit 140. Thus,dumping of the sand accumulated in the sand separator 130 into the sandpit 140 may include dumping via the first flow path (i.e., including theautomated choke 180 and the automated valves 185 a-b), the second flowpath (i.e., including the manual choke 190 and the manual valves 195a-b), or both. In some embodiments, the manual choke 190 and the manualvalves 195 a-b are provided for redundancy so that the automated choke180 and/or the automated valves 185 a-b can be taken out of service formaintenance, repair, or replacement without shutting down the sandseparation system 100.

As shown in FIG. 1, the sand pit 140 is adapted to receive the sandstream from the dump manifold 135, as indicated by arrow 165, which dumpmanifold 135 is consequently adapted to adjust the flow of the sandstream from the sand separator 130 to the sand pit 140. In someembodiments, the sand pit 140 is a stainless-steel vessel. In someembodiments, as in FIG. 1, the sand separation system 100 furtherincludes a level sensor 166 a and a weight sensor 166 b. Before, during,and/or after the sand pit 140 receives the sand stream from the dumpmanifold 135, as indicated by the arrow 165, the level sensor 166 a isadapted to monitor the amount of sand and fluid accumulated in the sandpit 140 and the weight sensor 166 b is adapted to monitor the weight ofthe sand accumulated in the sand pit 140. In some embodiments, as inFIG. 1, the one or more computers (e.g., the control unit 170) is/arefurther adapted to receive data/signals from the level sensor 166 a, theweight sensor 166 b, or both. In some embodiments, the level sensor 166a is, includes, or is part of a radar sensor, a guided wave radarsensor, an electronic float sensor, a thermal imaging device such as aFLIR camera, or any combination thereof. For example, the level sensor166 a may include multiple sensors to provide redundancy.

Referring collectively to FIGS. 1, 2A, and 2B, in operation, thewellbore slurry flows from the wellbore 105 to the sand separator 130via the wellhead 110 and the automated choke 120. In some embodiments,the flow of the wellbore slurry via the automated choke 120 may besupplemented with a manual choke that forms a choke manifold togetherwith the automated choke 120. As the wellbore slurry flows from thewellbore 105 to the sand separator 130, the one or more computers (e.g.,the control unit 170) communicate(s) control signals to the automatedchoke 120 and receive(s) data/signals from the pressure sensor 196. As aresult, the one or more computers is/are able to adjust the flow of thewellbore slurry from the wellbore 105 to the sand separator 130 (usingthe automated choke 120) and monitor the pressure of the wellbore slurryexiting the wellhead 110 (using the pressure sensor 196). Alternatively,the automated choke 120 may be omitted in favor of a manual choke viawhich the wellbore slurry flows from the wellbore 105 to the sandseparator 130. In any case, the sand separator 130 separates thewellbore slurry into the fluids stream, which is diverted to thepipeline 150, and the sand stream, which is diverted to the dumpmanifold 135.

As the wellbore slurry is separated into the fluids stream and the sandstream, the one or more computers (e.g., the control unit 170)receive(s) data/signals from the ultrasonic sensor 146 a, thetemperature sensor 146 b, the pressure sensor 146 c, the another levelsensor located internally within the sand separator 130, or anycombination thereof. As a result, the one or more computers is/are ableto monitor the amount of sand accumulated in the sand separator 130(using the ultrasonic sensor 146 a, the temperature sensor 146 b, orboth) and the pressure in the sand separator 130 (using the pressuresensor 146 c). Furthermore, as the fluids stream flows to the pipeline150, the one or more computers receive(s) data/signals from the sandsensor 156 a. As a result, the one or more computers is/are able tomonitor the amount of sand in the fluids stream exiting the sandseparator 130 (using the sand sensor 156 a). Alternatively, the sandsensor 156 a may be omitted so that the one or more computers is/are notable to monitor the amount of sand in the fluids stream exiting the sandseparator 130.

As desired or necessary, as determined by the one or more computers(e.g., the control unit 170), the sand stream flows from the sandseparator 130 to the sand pit 140 via the dump manifold 135. As the sandstream flows from the sand separator 130 to the sand pit 140, the one ormore computers communicate(s) control signals to the automated choke180, the automated valves 185 a-b, or any combination thereof, andreceives data/signals from the pressure sensor 176 a, the pressuresensor 176 b, the level sensor 166 a, the weight sensor 166 b, or anycombination thereof. As a result, the one or more computers is/are ableto adjust the flow of the sand stream from the sand separator 130 to thesand pit 140 via the first flow path (using the automated choke 180, theautomated valves 185 a-b, or any combination thereof) and monitor thepressure of the sand stream entering and exiting the dump manifold 135(using the pressure sensors 176 a-b, respectively), the amount of sandaccumulated in the sand pit 140 (using the level sensor 166 a), and theweight of the sand accumulated in the sand pit 140 (using the weightsensor 166 b). Furthermore, as the sand stream flows from the sandseparator 130 to the sand pit 140, the one or more computers receive(s)data/signals from the sand sensor 156 b. As a result, the one or morecomputers is/are able to monitor the amount of sand in the sand streamexiting the sand separator 130 (using the sand sensor 156 b).Alternatively, the sand sensor 156 b may be omitted so that the one ormore computers is/are not able to monitor the amount of sand in thefluids stream exiting the sand separator 130.

By adjusting the automated choke 120, the automated choke 180, theautomated valves 185 a-b, or any combination thereof, the one or morecomputers (e.g., the control unit 170) controls automated dumping of thesand stream from the sand separator 130 into the sand pit 140. In someembodiments, the one or more computers' automated control of theautomated choke 120, the automated choke 180, and the automated valves185 a-b is based on data/signals received from the ultrasonic sensor 146a, the temperature sensor 146 b, the pressure sensor 146 c, the sandsensor 156 a, the sand sensor 156 b, the level sensor 166 a, the weightsensor 166 b, the pressure sensors 176 a, 176 b, and/or 196, or anycombination thereof. In some embodiments, the one or more computers'automated control of the automated choke 120, the automated choke 180,and the automated valves 185 a-b is based on periodic dumping of thesand separator 130 at periodic predetermined time intervals. Such timeintervals may be adjusted occasionally by the one or more computersbased on data/signals received from the ultrasonic sensor 146 a, thetemperature sensor 146 b, the pressure sensor 146 c, the sand sensor 156a, the sand sensor 156 b, the level sensor 166 a, the weight sensor 166b, the pressure sensors 176 a, 176 b, and/or 196, or any combinationthereof. For example, data/signals received from the weight sensor 166 bmay be correlated by the one or more computers against the dumpfrequency and a known volume of the sand separator 130 to determinewhether or not to adjust the dump frequency.

Referring to FIG. 3, in an embodiment, a method of operating the sandseparation system 100 is generally referred to by the reference numeral200. The method 200 is carried out by receiving, at the one or morecomputers (e.g., the control unit 170), data/signals from the ultrasonicsensor 146 a, the temperature sensor 146 b, the pressure sensor 146 c,the sand sensor 156 a, the sand sensor 156 b, the level sensor 166 a,the weight sensor 166 b, the pressure sensor 176 a, the pressure sensor176 b, the pressure sensor 196, the another level sensor locatedinternally within the sand separator 130, or any combination thereof,and sending, from the one or more computers, control signals to theautomated choke 120, the automated choke 180, the automated valves 185a-b, or any combination thereof. The automated choke 120, the automatedchoke 180, and/or the automated valves 185 a-b are adapted to sendfeedback regarding their respective positions (i.e., the degree to whicheach is open, closed, or transitioning) to the one or more computers,which feedback is utilized by the one or more computers (in combinationwith the sensor data/signals) to determine how to actuate the automatedchoke 120, the automated choke 180, and/or the automated valves 185 a-b.

The method includes at a step 205, separating, using the sand separator130, sand from the wellbore slurry. At a step 210, the separated sand isaccumulated in the sand separator 130. At a step 215, a firstcharacteristic of the sand accumulated in the sand separator 130 ismeasured using a first sensor. In some embodiments of the step 215, thefirst sensor is the ultrasonic sensor 146 a and the first characteristicis the amount of sand accumulated in the sand separator 130. In otherembodiments of the step 215, the first sensor is the temperature sensor146 b and the first characteristic is the amount of sand accumulated inthe sand separator 130. In still other embodiments of the step 215, thefirst sensor is the pressure sensor 146 c and the first characteristicis the pressure in the sand separator 130. At a step 220, the one ormore computers (e.g., the control unit 170) controls, based on themeasured first characteristic: the automated choke 120 to feed thewellbore slurry into the sand separator 130; and/or the automated choke180 to dump the accumulated sand into the sand pit 140. At a step 225,the dumped sand is accumulated in the sand pit 140. At a step 230, asecond characteristic of the sand accumulated in the sand pit 140 ismeasured using a second sensor. In some embodiments of the step 230, thesecond sensor is the level sensor 166 a and the second characteristic isthe amount of sand accumulated in the sand pit 140. In other embodimentsof the step 230, the second sensor is the weight sensor 166 b and thesecond characteristic is the weight of the sand accumulated in the sandpit 140. Finally, at a step 235, the measured first and secondcharacteristics are compared using the one or more computers to verifythe accuracy of the first characteristic as measured by the firstsensor. In some embodiments, at the step 235, the measured first andsecond characteristics are compared using the one or more computers toverify the accuracy of the first characteristic as measured by the firstsensor, as well as the accuracy of the second characteristic as measuredby the second sensor. In some embodiments, at the step 235, the measuredfirst and second characteristics are compared using the one or morecomputers to verify the accuracy of the first characteristic as measuredby the first sensor, the accuracy of the second characteristic asmeasured by the second sensor, the overall operation of the system 100,or any combination thereof.

Referring to FIGS. 4A-4D, in an embodiment, the sand separation system100 further includes a sand detection system 240 including energygenerators 245 a-c and energy sensors 250 a-c retrofitted or otherwisemounted to the sand separator 130. In some embodiments, the sandseparator 130 is a known type of sand separator to which the energygenerators 245 a-c and the energy sensors 250 a-c are retrofitted. Inone or more embodiments, the known type of the sand separator may be orinclude, for example: a known configuration (e.g., spherical, vertical,etc.); a known separation technique (e.g., cyclonic); a brand (e.g.,Cameron®); a known size; a known working pressure or pressure rating; aknown working pressure range; or any combination thereof. For example,the known type of sand separator may be a Cameron® vertical sandseparator having a known size and known working pressure. For anotherexample, the known type of sand separator may be a cyclonic sandseparator. For yet another example, the known type of sand separator maybe a cyclonic sand separator having a known size. The sand separator 130defines an internal region 252 in which separated sand 254 is adapted tobe disposed. In some embodiments, the energy generators 245 a-c and theenergy sensors 250 a-c are mounted to the sand separator 130 outside ofthe internal region 252. In some embodiments, the energy generators 245a-c and the energy sensors 250 a-c are non-invasively mounted to thesand separator 130. In addition to the energy generators 245 a-c and theenergy sensors 250 a-c, the sand detection system 240 includes the oneor more computers (e.g., the control unit 170).

The energy generators 245 a-c are configured to impart energy to thesand separator 130 before, during, and/or after the sand separator 130separates the wellbore slurry into the fluids stream 155 and the sandstream 160. For example, the energy generators 245 a-c may be strikersconfigured to strike the sand separator 130, thereby imparting vibrationto the sand separator 130. In at least one such embodiment, the energygenerators 245 a-c are solenoids. For example, the energy generators 245a-c may be sealed linear solenoids, intermittent, push, 1″ Stroke, 68oz. force, available from McMASTER-CARR®, Part No. 69905K179. Inaddition, or instead, the energy generators 245 a-c may be emittersconfigured to emit electromagnetic or pressure (e.g., acoustic) wavesinto the sand separator 130. In some embodiments, as in FIGS. 4A-4D, theone or more computers (e.g., the control unit 170) is/are furtheradapted to communicate with the energy generators 245 a c. For example,the one or more computers may send control signals to the energygenerators 245 a-c and/or receive data from the energy generators 245 ac.

The energy generators 245 a-c are spaced vertically along the height ofthe sand separator 130. One or more of the energy generators 245 a-c maybe circumferentially aligned with one or more of the other energygenerators 245 a-c along the circumference of the sand separator 130, asshown in FIGS. 4A-4C. In addition, or instead, one or more of the energygenerators 245 a-c may be circumferentially offset from one or more ofthe other energy generators 245 a-c along the circumference of the sandseparator 130. Finally, although shown in FIGS. 4A-4D with the three (3)energy generators 245 a c, the sand detection system 240 may insteadinclude one (1), two (2), four (4) or more energy generators.

The energy sensors 250 a-c are configured to detect a response to theenergy imparted to the sand separator 130 by the energy generators 245a-c before, during, and/or after the sand separator 130 separates thewellbore slurry into the fluids stream 155 and the sand stream 160. Forexample, the energy sensors 250 a-c may be configured to detectvibration imparted to the sand separator 130 by the energy generators245 a-c (i.e., the strikers). In some embodiments, the energy sensors250 a-c are accelerometers. In some embodiments, the energy sensors 250a-c are triaxial accelerometers. For example, the energy sensors 250 a-cmay be triaxial ICP® accelerometers having 100 mV/g sensitivity and ¼-284-pin electrical connectors, available from The Modal Shop, PCBPiezotronics Model No. TLD356A14, Type SU, TEDS Version. Furthermore, inone embodiment the energy sensors 250 a-c may be wired using 4-conductorshielded cables having a 4-pin plug to (3) BNC plugs, available from TheModal Shop, PCB Piezotronics Model No. 010G50, Type SU. In addition, orinstead, the energy sensors 250 a-c may be configured to detectelectromagnetic or pressure (e.g., acoustic) waves emitted into the sandseparator 130 by the energy generators 245 a-c (or another source). Insome embodiments, as in FIGS. 4A-4D, the one or more computers (e.g.,the control unit 170) is/are further adapted to receive data/signalsfrom the energy sensors 250 a-c.

The energy sensors 250 a-c are spaced vertically along the height of thesand separator 130. One or more of the energy sensors 250 a-c may becircumferentially aligned with one or more of the other energy sensors250 a-c along the circumference of the sand separator 130, as shown inFIGS. 4A-4C. In addition, or instead, one or more of the energy sensors250 a-c may be circumferentially offset from one or more of the otherenergy sensors 250 a-c along the circumference of the sand separator130. Likewise, one or more of the energy sensors 250 a-c may becircumferentially offset from one or more of the energy generators 245a-c (e.g., by 180-degrees) along the circumference of the sand separator130, as shown in FIGS. 4A-4D. In addition, or instead, one or more ofthe energy sensors 250 a-c may be circumferentially aligned with one ormore of the energy generators 245 a-c along the circumference of thesand separator 130. Finally, although shown in FIGS. 4A-4D with thethree (3) energy sensors 250 a c, the sand detection system 240 mayinstead include one (1), two (2), four (4), or more energy sensors.

Referring to FIG. 5, with continuing reference to FIGS. 4A-4D, in anembodiment, a method is generally referred to by the reference numeral255. The method 255 includes at a step 260, determining, independentlyof the sand detection system 240, a first level of separated sand withinthe sand separator 130. For example, the first level of separated sandwithin the sand separator 130 may be determined based on data/signalsreceived from the ultrasonic sensor 146 a, the temperature sensor 146 b,the pressure sensor 146 c, the sand sensor 156 a, the sand sensor 156 b,the level sensor 166 a, the weight sensor 166 b, the pressure sensor 176a, the pressure sensor 176 b, the pressure sensor 196, the another levelsensor located internally within the sand separator 130, or anycombination thereof. For another example, the first level of separatedsand within the sand separator 130 may be determined based on visualand/or physical inspection of the sand separator 130. At a step 265,first energy is imparted to the sand separator 130 using one or more ofthe energy generators 245 a c. At a step 270, when the first level ofseparated sand is disposed within the sand separator 130, a firstresponse to the first energy imparted to the sand separator 130 isdetected using one or more of the energy sensors 250 a-c.

For example, the first level of separated sand within the sand separator130 may be the level of separated sand shown in FIG. 4A. For anotherexample, the first level of separated sand within the sand separator 130may be the level of separated sand shown in FIG. 4B. For yet anotherexample, the first level of separated sand within the sand separator 130may be the level of separated sand shown in FIG. 4C. For yet anotherexample, the first level of separated sand within the sand separator 130may be the level of separated sand shown in FIG. 4D.

At a step 275, a second level of separated sand within the sandseparator 130 is determined independently of the sand detection system240. For example, the second level of separated sand within the sandseparator 130 may be determined from data/signals received from theultrasonic sensor 146 a, the temperature sensor 146 b, the pressuresensor 146 c, the sand sensor 156 a, the sand sensor 156 b, the levelsensor 166 a, the weight sensor 166 b, the pressure sensor 176 a, thepressure sensor 176 b, the pressure sensor 196, the another level sensorlocated internally within the sand separator 130, or any combinationthereof. For another example, the second level of separated sand withinthe sand separator 130 may be determined via visual and/or physicalinspection of the sand separator 130. At a step 280, second energy isimparted to the sand separator 130 using one or more of the energygenerators 245 a c. At a step 285, when the second level of separatedsand is disposed within the sand separator 130, a second response to thesecond energy imparted to the sand separator 130 is detected using oneor more of the energy sensors 250 a-c.

The second level of separated sand within the sand separator 130 isdifferent than the first level of separated sand within the sandseparator 130. For example, the second level of separated sand withinthe sand separator 130 may be the level of separated sand shown in FIG.4A. For another example, the second level of separated sand within thesand separator 130 may be the level of separated sand shown in FIG. 4B.For yet another example, the second level of separated sand within thesand separator 130 may be the level of separated sand shown in FIG. 4C.For yet another example, the second level of separated sand within thesand separator 130 may be the level of separated sand shown in FIG. 4D.

At a step 290, the sand detection system 240 is tuned based on theindependently determined first level, the first response detected by theenergy sensor(s) 250 a c, the independently determined second level, andthe second response detected by the energy sensor(s) 250 a c. At a step295, third energy is imparted to the sand separator 130 using one ormore of the energy generators 245 a c. At a step 300, when the sandseparator 130 is filled with a third level of separated sand, a thirdresponse to the third energy imparted to the sand separator 130 isdetected using one or more of the energy sensors 250 a c.

The third level of separated sand within the sand separator 130 isdifferent than the first level of separated sand within the sandseparator 130 and the second level of separated sand within the sandseparator 130. For example, the third level of separated sand within thesand separator 130 may be the level of separated sand shown in FIG. 4A.For another example, the third level of separated sand within the sandseparator 130 may be the level of separated sand shown in FIG. 4B. Foryet another example, the third level of separated sand within the sandseparator 130 may be the level of separated sand shown in FIG. 4C. Foryet another example, the third level of separated sand within the sandseparator 130 may be the level of separated sand shown in FIG. 4D.

At a step 305, the third level of separated sand in the sand separator130 is determined, using the sand detection system 240, based on thetuning of the sand detection system 240 and the third response detectedby the energy sensor(s) 250 a c. Finally, at a step 310, at least aportion of the separated sand is dumped from the sand separator 130based on the determined third ratio.

Referring to FIGS. 6A-6C, in an embodiment, a sand separation system isgenerally referred to by the reference numeral 100′ and includes severalfeatures and/or components substantially identical to correspondingfeatures and/or components of the sand separation system 100, whichsubstantially identical features and/or components are given the samereference numerals, except that the suffix “′” is added. Accordingly,the sand separation system 100′ includes a sand separator 130′ (e.g., ofa known type). The sand separator 130′ defines an internal region 252′in which separated sand 254′ is adapted to be disposed. Energygenerators 245 a′-245 c′ are adapted to impart energy to the sandseparator 130′. In some embodiments, the energy generators 245 a′-245 c′are mounted to the sand separator 130′ outside of the internal region252′. In some embodiments, the energy generators 245 a′-245 c′ arenon-invasively mounted to the sand separator 130′. In some embodiments,the energy generators 245 a′-245 c′ comprise strikers and the energyimparted to the sand separator 130′ comprises one or more impactsadministered against the sand separator 130′ by the strikers. Energysensors 250 a′-250 c′ are adapted to detect a response to the energyimparted to the sand separator 130′ by the energy generators 245 a′-245c′. In some embodiments, the energy sensors 250 a′-250 c′ are mounted tothe sand separator 130′ outside of the internal region 252′. In someembodiments, the energy sensors 250 a′-250 c′ are non-invasively mountedto the sand separator 130′. In some embodiments, the response detectedby the energy sensors 250 a′-250 c′ comprises a vibrational responsecaused by the one or more impacts administered against the sandseparator 130′ by the strikers. One or more computers (e.g., a controlunit 170′) is/are adapted to communicate with the energy sensors 250a′-250 c′ and the energy generators 245 a′-245 c′, the one or morecomputers being configured to determine an unknown sand level in thesand separator 130′.

In one or more embodiments, the energy generators 245 a′-245 c′, theenergy sensors 250 a′-250 c′, and the one or more computers (e.g., thecontrol unit 170′), or any combination thereof, are “pre-tuned” basedon: known sand level(s) in: the sand separator 130′, and/or another sandseparator (e.g., the sand separator 130); and detected response(s) toenergy imparted to: the sand separator 130′ when the sand separator 130′is filled with the known sand level(s), and/or the another sandseparator (e.g., the sand separator 130) when the another sand separatoris filled with the known sand level(s). For example, in one or moreembodiments, the pre-tuning of the energy generators 245 a′-245 c′, theenergy sensors 250 a′-250 c′, the one or more computers, or the anycombination thereof, may be based at least partially on the execution ofthe method 255. More particularly, such pre-tuning may be based on thefirst sand level independently determined at the step 260 of the method255, the first response detected by the energy sensor(s) 250 a-c at thestep 270 of the method 255, the second sand level independentlydetermined at the step 275 of the method 255, and the second responsedetected by the energy sensor(s) 250 a-c at the step 285 of the method255. Finally, the one or more computers (e.g., the control unit 170′)are configured to determine the unknown sand level in the sand separator130′ based on: the response detected by the one or more energy sensors250 a′-250 c′; and the pre-tuning of the one or more computers, the oneor more energy sensors 250 a′-250 c′, the one or more energy generators245 a′-245 b′, or the any combination thereof.

Referring to FIG. 7, with continuing reference to FIGS. 6A-6C, in anembodiment, a method for the sand separation system 100′ is generallyreferred to by the reference numeral 315. The method 315 generallyincludes at a step 320 mounting the energy generator(s) 245 a′-245 c′ tothe sand separator 130′. For example, the energy generator(s) 245 a′-245c′ may be mounted to the sand separator 130′ outside of the internalregion 252′. For another example, the energy generator(s) 245 a′-245 c′may be non-invasively mounted to the sand separator 130′. At a step 325,the energy sensor(s) are mounted to the sand separator 130′. Forexample, the energy sensor(s) may be mounted to the sand separator 130′outside of the internal region 252′. For another example, the energysensor(s) may be non-invasively mounted to the sand separator 130′. At astep 330, using the energy generator(s) 245 a′-245 c′, energy isimparted to the sand separator 130′. More particularly, the one or morecomputers (e.g., the control unit 170′) communicate(s) control signalsto the energy generator(s) 245 a′-245 c′ to cause the energygenerator(s) 245 a′-245 c′ to impart the energy to the sand separator130′. For example, the energy imparted to the sand separator 130′ by theenergy generator(s) 245 a′-245 c′ may include one or more impactsadministered against the sand separator 130′. At a step 335, using theenergy sensor(s), a response to the energy imparted to the sandseparator 130′ is detected. More particularly, the one or more computersreceive data/signals from the energy sensor(s) 250 a′-250 c′ based onthe response to the energy imparted to the sand separator 130′ when thesand separator 130′ is filled with an unknown level of separated sand.For example, the response detected by the energy sensor(s) may include avibrational response caused by the one or more impacts administeredagainst the sand separator 130′. At a step 340, using the one or morecomputers, the unknown sand level in the sand separator 130′ isdetermined based on: the response detected by the energy sensor(s); andthe pre-tuning of the one or more computers, the one or more energysensor(s), the one or more energy generator(s) 245 a′-245 c′, or the anycombination thereof.

Finally, at a step 345, separated sand is dumped from the sand separator130′ based on the determined unknown sand level. More particularly, insome embodiments, as in FIG. 6A, the one or more computers (e.g., thecontrol unit 170′) facilitate(s) the dumping of the at least a portionof the separated sand from the sand separator 130′ by communicating an“alarm” signal to a user when the level of separated sand in the sandseparator 130′ exceeds a predetermined threshold. The user then causesthe dumping of the at least a portion of the separated sand from thesand separator 130′ by actuating (e.g., manually) the dump manifold 135′to effectuate a dumping cycle. In other embodiments, as in FIG. 6B, theone or more computers facilitate(s) the dumping of the at least aportion of the separated sand from the sand separator 130′ bycommunicating an “alarm” signal to a user when the level of separatedsand in the sand separator 130′ exceeds a predetermined threshold. Theuser then communicates an “input” back to the one or more computers(e.g., “approve dump”) and, based on the user's input, the one or morecomputers cause(s) the dumping of the at least a portion of theseparated sand from the sand separator 130′ by communicating “open” and“close” control signals to the dump manifold 135′ to effectuate adumping cycle. In still other embodiments, as in FIG. 6C, based on thedata/signals received from the energy sensors 250 a′-250 c′ without anyuser input, the one or more computers cause(s) the dumping of the atleast a portion of the separated sand from the sand separator 130′ byautomatically communicating “open” and “close” control signals to thedump manifold 135′ to effectuate a dumping cycle.

Referring to FIG. 8, in an embodiment, a computing node 1000 forimplementing one or more embodiments of one or more of theabove-described elements, computers, control units (e.g., 170 and/or170′), systems (e.g., 100 and/or 100′), methods (e.g., 200 and/or 315)and/or steps (e.g., 205, 210, 215, 220, 225, 230, 235, 320, 325, 330,335, 340, and/or 345), or any combination thereof, is depicted. Moreparticularly, in several embodiments, the node 1000 is, includes, or ispart of the control unit 170 (or the control unit 170′) so as to providefor autonomous or stand-alone operation of the system 100 (or the system100′) and/or execution of the method 200 (or the method 315). The node1000 includes a microprocessor 1000 a, an input device 1000 b, a storagedevice 1000 c, a video controller 1000 d, a system memory 1000 e, adisplay 1000 f, and a communication device 1000 g all interconnected byone or more buses 1000 h. In several embodiments, the storage device1000 c may include a floppy drive, hard drive, CD-ROM, optical drive,any other form of storage device or any combination thereof. In severalembodiments, the storage device 1000 c may include, and/or be capable ofreceiving, a floppy disk, CD-ROM, DVD-ROM, or any other form ofcomputer-readable medium that may contain executable instructions. Inseveral embodiments, the communication device 1000 g may include amodem, network card, or any other device to enable the node 1000 tocommunicate with other nodes. In several embodiments, any noderepresents a plurality of interconnected (whether by intranet orInternet) computer systems, including without limitation, personalcomputers, mainframes, PDAs, smartphones and cell phones.

In several embodiments, one or more of the components of any of theabove-described systems include at least the node 1000 and/or componentsthereof, and/or one or more nodes that are substantially similar to thenode 1000 and/or components thereof. In several embodiments, one or moreof the above-described components of the node 1000 and/or theabove-described systems include respective pluralities of samecomponents.

In several embodiments, a computer system typically includes at leasthardware capable of executing machine readable instructions, as well asthe software for executing acts (typically machine-readableinstructions) that produce a desired result. In several embodiments, acomputer system may include hybrids of hardware and software, as well ascomputer sub-systems.

In several embodiments, hardware generally includes at leastprocessor-capable platforms, such as client-machines (also known aspersonal computers or servers), and hand-held processing devices (suchas smart phones, tablet computers, personal digital assistants (PDAs),or personal computing devices (PCDs), for example). In severalembodiments, hardware may include any physical device that is capable ofstoring machine-readable instructions, such as memory or other datastorage devices. In several embodiments, other forms of hardware includehardware sub-systems, including transfer devices such as modems, modemcards, ports, and port cards, for example.

In several embodiments, software includes any machine code stored in anymemory medium, such as RAM or ROM, and machine code stored on otherdevices (such as floppy disks, flash memory, or a CD ROM, for example).In several embodiments, software may include source or object code. Inseveral embodiments, software encompasses any set of instructionscapable of being executed on a node such as, for example, on a clientmachine or server.

In several embodiments, combinations of software and hardware could alsobe used for providing enhanced functionality and performance for certainembodiments of the present disclosure. In an embodiment, softwarefunctions may be directly manufactured into a silicon chip. Accordingly,it should be understood that combinations of hardware and software arealso included within the definition of a computer system and are thusenvisioned by the present disclosure as possible equivalent structuresand equivalent methods.

In several embodiments, computer readable mediums include, for example,passive data storage, such as a random access memory (RAM) as well assemi-permanent data storage such as a compact disk read only memory(CD-ROM). One or more embodiments of the present disclosure may beembodied in the RAM of a computer to transform a standard computer intoa new specific computing machine. In several embodiments, datastructures are defined organizations of data that may enable anembodiment of the present disclosure. In an embodiment, a data structuremay provide an organization of data, or an organization of executablecode.

In several embodiments, any networks and/or one or more portionsthereof, may be designed to work on any specific architecture. In anembodiment, one or more portions of any networks may be executed on asingle computer, local area networks, client-server networks, wide areanetworks, internets, hand-held and other portable and wireless devicesand networks.

In several embodiments, a database may be any standard or proprietarydatabase software. In several embodiments, the database may have fields,records, data, and other database elements that may be associatedthrough database specific software. In several embodiments, data may bemapped. In several embodiments, mapping is the process of associatingone data entry with another data entry. In an embodiment, the datacontained in the location of a character file can be mapped to a fieldin a second table. In several embodiments, the physical location of thedatabase is not limiting, and the database may be distributed. In anembodiment, the database may exist remotely from the server, and run ona separate platform. In an embodiment, the database may be accessibleacross the Internet. In several embodiments, more than one database maybe implemented.

In several embodiments, a plurality of instructions stored on anon-transitory computer readable medium may be executed by one or moreprocessors to cause the one or more processors to carry out or implementin whole or in part the above-described operation of each of theabove-described elements, computers, control units (e.g., 170 and/or170′), systems (e.g., 100 and/or 100′), methods (e.g., 200 and/or 315)and/or steps (e.g., 205, 210, 215, 220, 225, 230, 235, 320, 325, 330,335, 340, and/or 345), or any combination thereof. In severalembodiments, such a processor may include one or more of themicroprocessor 1000 a, any processor(s) that are part of the componentsof the above-described systems, and/or any combination thereof, and sucha computer readable medium may be distributed among one or morecomponents of the above-described systems. In several embodiments, sucha processor may execute the plurality of instructions in connection witha virtual computer system. In several embodiments, such a plurality ofinstructions may communicate directly with the one or more processors,and/or may interact with one or more operating systems, middleware,firmware, other applications, and/or any combination thereof, to causethe one or more processors to execute the instructions.

A sand separation system has been disclosed. The sand separation systemgenerally includes a sand separator of a known type, wherein the sandseparator of the known type defines an internal region in whichseparated sand is adapted to be disposed; one or more energy generatorsadapted to impart energy to the sand separator of the known type,wherein the one or more energy generators are mounted to the sandseparator of the known type outside of the internal region, wherein theone or more energy generators include one or more strikers, and whereinthe energy imparted to the sand separator of the known type includes oneor more impacts administered against the sand separator of the knowntype by the one or more strikers; one or more energy sensors adapted todetect a response to the energy imparted to the sand separator of theknown type, wherein the one or more energy sensors are mounted to thesand separator of the known type outside of the internal region, andwherein the response detected by the one or more energy sensors includesa vibrational response caused by the one or more impacts administeredagainst the sand separator of the known type by the one or morestrikers; and one or more computers adapted to communicate with the oneor more energy sensors and the one or more energy generators, the one ormore computers being configured to determine an unknown sand level inthe sand separator of the known type; wherein the one or more computers,the one or more energy sensors, the one or more energy generators, orany combination thereof are pre-tuned based on: known sand level(s) in:the sand separator of the known type, and/or another sand separator ofthe known type, and detected response(s) to energy imparted to: the sandseparator of the known type when the sand separator of the known type isfilled with the known sand level(s), and/or the another sand separatorof the known type when the another sand separator of the known type isfilled with the known sand level(s); and wherein the one or morecomputers are configured to determine the unknown sand level in the sandseparator of the known type based on: the response detected by the oneor more energy sensors, and the pre-tuning of the one or more computers,the one or more energy sensors, the one or more energy generators, orthe any combination thereof. In one or more embodiments, the one or moreenergy sensors are non-invasively mounted to the sand separator of theknown type; and the one or more energy generators are non-invasivelymounted to the sand separator of the known type. In one or moreembodiments, the one or more computers, the one or more energy sensors,the one or more energy generators, or the any combination thereof arepre-tuned based on: the known sand level(s) in the sand separator of theknown type; and the detected response(s) to the energy imparted to thesand separator of the known type when the sand separator of the knowntype is filled with the known sand level(s). In one or more embodiments,the one or more computers, the one or more energy sensors, the one ormore energy generators, or the any combination thereof are pre-tunedbased on: the known sand level(s) in the another sand separator of theknown type; and the detected response(s) to the energy imparted to theanother sand separator of the known type when the another sand separatorof the known type is filled with the known sand level(s).

A method for a sand separation system has also been disclosed. Themethod generally includes mounting one or more energy generators to asand separator of a known type, wherein the sand separator of the knowntype defines an internal region in which separated sand is adapted to bedisposed, and wherein mounting the one or more energy generators to thesand separator of the known type includes mounting the one or moreenergy generators to the sand separator of the known type outside of theinternal region; mounting one or more energy sensors to the sandseparator of the known type outside of the internal region; imparting,using the one or more energy generators, energy to the sand separator ofthe known type, wherein imparting the energy to the sand separator ofthe known type includes administering one or more impacts against thesand separator of the known type; detecting, using the one or moreenergy sensors, a response to the energy imparted to the sand separatorof the known type, wherein the response detected by the one or moreenergy sensors includes a vibrational response caused by the one or moreimpacts administered against the sand separator of the known type by theone or more strikers; and determining, using one or more computers, anunknown sand level in the sand separator of the known type, the one ormore computers being adapted to communicate with the one or more energysensors and the one or more energy generators; wherein the one or morecomputers, the one or more energy sensors, the one or more energygenerators, or any combination thereof are pre-tuned based on: knownsand level(s) in: the sand separator of the known type, and/or anothersand separator of the known type, and detected response(s) to energyimparted to: the sand separator of the known type when the sandseparator of the known type is filled with the known sand level(s),and/or the another sand separator of the known type when the anothersand separator of the known type is filled with the known sand level(s);and wherein the one or more computers determine the unknown sand levelin the sand separator of the known type based on: the response detectedby the one or more energy sensors, and the pre-tuning of the one or morecomputers, the one or more energy sensors, the one or more energygenerators, or the any combination thereof. In one or more embodiments,mounting the one or more energy generators to the sand separator of theknown type outside of the internal region includes non-invasivelymounting the one or more energy generators to the sand separator of theknown type; and mounting the one or more energy sensors to the sandseparator of the known type outside of the internal region includesnon-invasively mounting the one or more energy sensors to the sandseparator of the known type. In one or more embodiments, the one or morecomputers, the one or more energy sensors, the one or more energygenerators, or the any combination thereof are pre-tuned based on: theknown sand level(s) in the sand separator of the known type; and thedetected response(s) to the energy imparted to the sand separator of theknown type when the sand separator of the known type is filled with theknown sand level(s). In one or more embodiments, the one or morecomputers, the one or more energy sensors, the one or more energygenerators, or the any combination thereof are pre-tuned based on: theknown sand level(s) in the another sand separator of the known type; andthe detected response(s) to the energy imparted to the another sandseparator of the known type when the another sand separator of the knowntype is filled with the known sand level(s).

A system for a sand separator of a known type has also been disclosed.The system generally includes one or more energy sensors adapted todetect a response to energy imparted to the sand separator of the knowntype; and one or more computers adapted to communicate with the one ormore energy sensors, the one or more computers being configured todetermine an unknown sand level in the sand separator of the known type;wherein the one or more computers and/or the one or more energy sensorsare pre-tuned based on: known sand level(s) in: the sand separator ofthe known type, and/or another sand separator of the known type, anddetected response(s) to energy imparted to: the sand separator of theknown type when the sand separator of the known type is filled with theknown sand level(s), and/or the another sand separator of the known typewhen the another sand separator of the known type is filled with theknown sand level(s); and wherein the one or more computers areconfigured to determine the unknown sand level in the sand separator ofthe known type based on: the response detected by the one or more energysensors, and the pre-tuning of the one or more energy sensors and/or theone or more computers. In one or more embodiments, the energy isimparted to the sand separator of the known type by one or more impactsadministered against the sand separator of the known type; and theresponse includes a vibrational response caused by the one or moreimpacts administered against the sand separator of the known type. Inone or more embodiments, the system further includes the sand separatorof the known type; wherein the one or more energy sensors arenon-invasively mounted to the sand separator of the known type. In oneor more embodiments, the system further includes the sand separator ofthe known type; wherein the sand separator of the known type defines aninternal region in which separated sand is adapted to be disposed; andwherein the one or more energy sensors are mounted to the sand separatorof the known type outside of the internal region. In one or moreembodiments, the system further includes: one or more energy generatorsadapted to impart the energy to the sand separator of the known type;wherein the one or more computers are further adapted to communicatewith the one or more energy generators. In one or more embodiments, theone or more energy generators include one or more strikers; the energyimparted to the sand separator of the known type includes one or moreimpacts administered against the sand separator of the known type by theone or more strikers; and the response detected by the one or moreenergy sensors includes a vibrational response caused by the one or moreimpacts administered against the sand separator of the known type by theone or more strikers. In one or more embodiments, the system furtherincludes the sand separator of the known type; wherein the one or moreenergy sensors are non-invasively mounted to the sand separator of theknown type; and wherein the one or more energy generators arenon-invasively mounted to the sand separator of the known type. In oneor more embodiments, the system further includes the sand separator ofthe known type; wherein the sand separator of the known type defines aninternal region in which separated sand is adapted to be disposed;wherein the one or more energy sensors are mounted to the sand separatorof the known type outside of the internal region; and wherein the one ormore energy generators are mounted to the sand separator of the knowntype outside of the internal region. In one or more embodiments, the oneor more computers and/or the one or more energy sensors are pre-tunedbased on: the known sand level(s) in the sand separator of the knowntype; and the detected response(s) to the energy imparted to the sandseparator of the known type when the sand separator of the known type isfilled with the known sand level(s). In one or more embodiments, the oneor more computers and/or the one or more energy sensors are pre-tunedbased on: the known sand level(s) in the another sand separator of theknown type; and the detected response(s) to the energy imparted to theanother sand separator of the known type when the another sand separatorof the known type is filled with the known sand level(s).

A method for a sand separator of a known type has also been disclosed.The method generally includes detecting, using one or more energysensors, a response to energy imparted to the sand separator of theknown type; and determining, using one or more computers, an unknownsand level in the sand separator of the known type, the one or morecomputers being adapted to communicate with the one or more energysensors; wherein the one or more computers and/or the one or more energysensors are pre-tuned based on: known sand level(s) in: the sandseparator of the known type, and/or another sand separator of the knowntype, and detected response(s) to energy imparted to: the sand separatorof the known type when the sand separator of the known type is filledwith the known sand level(s), and/or the another sand separator of theknown type when the another sand separator of the known type is filledwith the known sand level(s); and wherein the one or more computersdetermine the unknown sand level in the sand separator of the known typebased on: the response detected by the one or more energy sensors, andthe pre-tuning of the one or more energy sensors and/or the one or morecomputers. In one or more embodiments, the method further includesimparting the energy to the sand separator of the known type; whereinimparting the energy to the sand separator of the known type includesadministering one or more impacts against the sand separator of theknown type; and wherein detecting, using the one or more energy sensors,the response to the energy imparted to the sand separator of the knowntype includes detecting, using the one or more energy sensors, avibrational response caused by the one or more impacts beingadministered against the sand separator of the known type. In one ormore embodiments, the method further includes non-invasively mountingthe one or more energy sensors to the sand separator of the known type.In one or more embodiments, the sand separator of the known type definesan internal region in which separated sand is adapted to be disposed;and the method further includes mounting the one or more energy sensorsto the sand separator of the known type outside of the internal region.In one or more embodiments, the method further includes imparting, usingone or more energy generators, the energy to the sand separator of theknown type; wherein the one or more computers are further adapted tocommunicate with the one or more energy generators. In one or moreembodiments, imparting, using the one or more energy generators, theenergy to the sand separator of the known type includes administeringone or more impacts against the sand separator of the known type; anddetecting, using the one or more energy sensors, the response to theenergy imparted to the sand separator of the known type includesdetecting, using the one or more energy sensors, a vibrational responsecaused by the one or more impacts being administered against the sandseparator of the known type. In one or more embodiments, the methodfurther includes non-invasively mounting the one or more energy sensorsto the sand separator of the known type; and non-invasively mounting theone or more energy generators to the sand separator of the known type.In one or more embodiments, the sand separator of the known type definesan internal region in which separated sand is adapted to be disposed;and the method further includes: mounting the one or more energy sensorsto the sand separator of the known type outside of the internal region;and mounting the one or more energy generators to the sand separator ofthe known type outside of the internal region. In one or moreembodiments, the one or more computers and/or the one or more energysensors are pre-tuned based on: the known sand level(s) in the sandseparator of the known type; and the detected response(s) to the energyimparted to the sand separator of the known type when the sand separatorof the known type is filled with the known sand level(s). In one or moreembodiments, the one or more computers and/or the one or more energysensors are pre-tuned based on: the known sand level(s) in the anothersand separator of the known type; and the detected response(s) to theenergy imparted to the another sand separator of the known type when theanother sand separator of the known type is filled with the known sandlevel(s).

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the present disclosure.

In several embodiments, the elements and teachings of the variousembodiments may be combined in whole or in part in some or all of theembodiments. In addition, one or more of the elements and teachings ofthe various embodiments may be omitted, at least in part, and/orcombined, at least in part, with one or more of the other elements andteachings of the various embodiments.

Any spatial references, such as, for example, “upper,” “lower,” “above,”“below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,”“upwards,” “downwards,” “side-to-side,” “left-to-right,”“right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,”“bottom-up,” “top-down,” etc., are for the purpose of illustration onlyand do not limit the specific orientation or location of the structuredescribed above.

In several embodiments, while different steps, processes, and proceduresare described as appearing as distinct acts, one or more of the steps,one or more of the processes, and/or one or more of the procedures mayalso be performed in different orders, simultaneously and/orsequentially. In several embodiments, the steps, processes, and/orprocedures may be merged into one or more steps, processes and/orprocedures.

In several embodiments, one or more of the operational steps in eachembodiment may be omitted. Moreover, in some instances, some features ofthe present disclosure may be employed without a corresponding use ofthe other features. Moreover, one or more of the above-describedembodiments and/or variations may be combined in whole or in part withany one or more of the other above-described embodiments and/orvariations.

Although several embodiments have been described in detail above, theembodiments described are illustrative only and are not limiting, andthose skilled in the art will readily appreciate that many othermodifications, changes and/or substitutions are possible in theembodiments without materially departing from the novel teachings andadvantages of the present disclosure. Accordingly, all suchmodifications, changes, and/or substitutions are intended to be includedwithin the scope of this disclosure as defined in the following claims.In the claims, any means-plus-function clauses are intended to cover thestructures described herein as performing the recited function and notonly structural equivalents, but also equivalent structures. Moreover,it is the express intention of the applicant not to invoke 35 U.S.C. §112(f) for any limitations of any of the claims herein, except for thosein which the claim expressly uses the word “means” together with anassociated function.

What is claimed is:
 1. A system for a sand separator of a known type,the system comprising: one or more energy sensors adapted to detect aresponse to energy imparted to the sand separator of the known type; andone or more computers adapted to communicate with the one or more energysensors, the one or more computers being configured to determine anunknown sand level in the sand separator of the known type; wherein theone or more computers and/or the one or more energy sensors arepre-tuned based on: known sand level(s) in: the sand separator of theknown type, and/or another sand separator of the known type, anddetected response(s) to energy imparted to: the sand separator of theknown type when the sand separator of the known type is filled with theknown sand level(s), and/or the another sand separator of the known typewhen the another sand separator of the known type is filled with theknown sand level(s); and wherein the one or more computers areconfigured to determine the unknown sand level in the sand separator ofthe known type based on: the response detected by the one or more energysensors, and the pre-tuning of the one or more energy sensors and/or theone or more computers.
 2. The system of claim 1, wherein the energy isimparted to the sand separator of the known type by one or more impactsadministered against the sand separator of the known type; and whereinthe response comprises a vibrational response caused by the one or moreimpacts administered against the sand separator of the known type. 3.The system of claim 1, further comprising: the sand separator of theknown type; wherein the one or more energy sensors are non-invasivelymounted to the sand separator of the known type.
 4. The system of claim1, further comprising: the sand separator of the known type; wherein thesand separator of the known type defines an internal region in whichseparated sand is adapted to be disposed; and wherein the one or moreenergy sensors are mounted to the sand separator of the known typeoutside of the internal region.
 5. The system of claim 1, furthercomprising: one or more energy generators adapted to impart the energyto the sand separator of the known type; wherein the one or morecomputers are further adapted to communicate with the one or more energygenerators.
 6. The system of claim 5, wherein the one or more energygenerators comprise one or more strikers; wherein the energy imparted tothe sand separator of the known type comprises one or more impactsadministered against the sand separator of the known type by the one ormore strikers; and wherein the response detected by the one or moreenergy sensors comprises a vibrational response caused by the one ormore impacts administered against the sand separator of the known typeby the one or more strikers.
 7. The system of claim 5, furthercomprising: the sand separator of the known type; wherein the one ormore energy sensors are non-invasively mounted to the sand separator ofthe known type; and wherein the one or more energy generators arenon-invasively mounted to the sand separator of the known type.
 8. Thesystem of claim 5, further comprising: the sand separator of the knowntype; wherein the sand separator of the known type defines an internalregion in which separated sand is adapted to be disposed; wherein theone or more energy sensors are mounted to the sand separator of theknown type outside of the internal region; and wherein the one or moreenergy generators are mounted to the sand separator of the known typeoutside of the internal region.
 9. The system of claim 1, wherein theone or more computers and/or the one or more energy sensors arepre-tuned based on: the known sand level(s) in the sand separator of theknown type; and the detected response(s) to the energy imparted to thesand separator of the known type when the sand separator of the knowntype is filled with the known sand level(s).
 10. The system of claim 1,wherein the one or more computers and/or the one or more energy sensorsare pre-tuned based on: the known sand level(s) in the another sandseparator of the known type; and the detected response(s) to the energyimparted to the another sand separator of the known type when theanother sand separator of the known type is filled with the known sandlevel(s).
 11. A method for a sand separator of a known type, the methodcomprising: detecting, using one or more energy sensors, a response toenergy imparted to the sand separator of the known type; anddetermining, using one or more computers, an unknown sand level in thesand separator of the known type, the one or more computers beingadapted to communicate with the one or more energy sensors; wherein theone or more computers and/or the one or more energy sensors arepre-tuned based on: known sand level(s) in: the sand separator of theknown type, and/or another sand separator of the known type, anddetected response(s) to energy imparted to: the sand separator of theknown type when the sand separator of the known type is filled with theknown sand level(s), and/or the another sand separator of the known typewhen the another sand separator of the known type is filled with theknown sand level(s); and wherein the one or more computers determine theunknown sand level in the sand separator of the known type based on: theresponse detected by the one or more energy sensors, and the pre-tuningof the one or more energy sensors and/or the one or more computers. 12.The method of claim 11, further comprising: imparting the energy to thesand separator of the known type; wherein imparting the energy to thesand separator of the known type comprises administering one or moreimpacts against the sand separator of the known type; and whereindetecting, using the one or more energy sensors, the response to theenergy imparted to the sand separator of the known type comprisesdetecting, using the one or more energy sensors, a vibrational responsecaused by the one or more impacts being administered against the sandseparator of the known type.
 13. The method of claim 11, furthercomprising: non-invasively mounting the one or more energy sensors tothe sand separator of the known type.
 14. The method of claim 11,wherein the sand separator of the known type defines an internal regionin which separated sand is adapted to be disposed; and wherein themethod further comprises mounting the one or more energy sensors to thesand separator of the known type outside of the internal region.
 15. Themethod of claim 11, further comprising: imparting, using one or moreenergy generators, the energy to the sand separator of the known type;wherein the one or more computers are further adapted to communicatewith the one or more energy generators.
 16. The method of claim 15,wherein imparting, using the one or more energy generators, the energyto the sand separator of the known type comprises administering one ormore impacts against the sand separator of the known type; and whereindetecting, using the one or more energy sensors, the response to theenergy imparted to the sand separator of the known type comprisesdetecting, using the one or more energy sensors, a vibrational responsecaused by the one or more impacts being administered against the sandseparator of the known type.
 17. The method of claim 15, furthercomprising: non-invasively mounting the one or more energy sensors tothe sand separator of the known type; and non-invasively mounting theone or more energy generators to the sand separator of the known type.18. The method of claim 15, wherein the sand separator of the known typedefines an internal region in which separated sand is adapted to bedisposed; and wherein the method further comprises: mounting the one ormore energy sensors to the sand separator of the known type outside ofthe internal region; and mounting the one or more energy generators tothe sand separator of the known type outside of the internal region. 19.The method of claim 11, wherein the one or more computers and/or the oneor more energy sensors are pre-tuned based on: the known sand level(s)in the sand separator of the known type; and the detected response(s) tothe energy imparted to the sand separator of the known type when thesand separator of the known type is filled with the known sand level(s).20. The method of claim 11, wherein the one or more computers and/or theone or more energy sensors are pre-tuned based on: the known sandlevel(s) in the another sand separator of the known type; and thedetected response(s) to the energy imparted to the another sandseparator of the known type when the another sand separator of the knowntype is filled with the known sand level(s).